Development of a Lightweight Forged Magnesium Aircraft ... · Development of a Lightweight Forged...

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EXCELLENCE • ACCOUNTABILITY • INNOVATION HEALTHCARE PROTECTION SPECIALITY ENVIRONMENTAL

Development of a Lightweight

Forged Magnesium Aircraft

Seat Component Eighth Triennial International Aircraft Fire

and Cabin Safety Research Conference

27th October 2016

Dominic Henry – Magnesium Elektron

Martin Kemp – Altair Product Design


EXCELLENCE • ACCOUNTABILITY • INNOVATION

Agenda

• Introduction

– Magnesium Elektron

– Magnesium in the aircraft cabin

• Development of lightweight forged aircraft seat components

– Intro to Featherlite Aircraft Seat NATEP project

– Data generation and properties

– FEA simulation development

– Forging – Buy to Fly ratio improvement

– Machining – fast & efficient dry machining

– Dynamic Testing – 16 G

• Summary



Wrought Products

Casting Alloys

Powders

Recycling

Biomedical

Aerospace, Automotive, Defence, Biomaterials, Graphic Arts, Oil & Gas, Speciality

9 manufacturing sites in the

UK, Europe & North America

500 employees worldwide

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=h19ChFP_Kom9rM&tbnid=V14Uz0n1dxV8cM:&ved=0CAUQjRw&url=http://solarracing.gatech.edu/node/29&ei=cBl6U5zwB-ee7Abr-4GIDg&bvm=bv.66917471,d.ZWU&psig=AFQjCNHHQ4vPBWPAcew_ZOjbiWAPQw7-NQ&ust=1400597230570020



…. it appears that certain magnesium alloys may have flammability properties acceptable

for use in aircraft seat structure ….

Example of no burning

after melting

(Elektron 43 & Elektron 21)

Example of burning after

Melting (AZ31)

AS8049C: “Magnesium alloys may be used in aircraft seat construction provided they

are tested to and meet the flammability performance requirements in the FAA Fire

Safety Branch document: Aircraft Materials Fire Test Handbook – DOT/FAA/AR-00/12,

Chapter 25, Oil Burner Flammability Test for Magnesium Alloy Seat Structure.”

SAE International Aerospace Standard – AS8049B

Para 3.3.3 “Magnesium alloys shall not be used.”

Magnesium – Aircraft Cabin Regulations



What is Elektron®43?

• Elektron® 43: The latest wrought

magnesium aerospace alloy

• Elektron ®43: Available as plate, extrusion,

forging stock.

– AMS 4371 - Plate Precipitation Heat Treated

– AMS 4485 - Extrusions Precipitation Heat Treated

– MMPDS: Contains –A and –B basis statistical minima



Eurocopter EC120

Bell Agusta 609

MD Helicopter: MD600N

Where are WE43 alloys used?

https://upload.wikimedia.org/wikipedia/commons/d/d9/N600SY-MD600N-Shoreham2003-61.JPG



Agenda

• Introduction to










• Summary



Featherlite Aircraft Seat Project

o UK Government backed scheme - National

Aerospace Technology Exploitation Program

o Lightweighting offers economic and environmental

benefits

o Reduced fuel burn and CO2 emissions.

o Reduce barriers to aircraft interiors OEM’s using UK

sourced high performance magnesium alloys

o Develop forging and machining technology to ensure

UK based supply chain is economically and technically

capable of providing weight saving in the cabin

o Establish a UK based supply chain with a potential

global end market not just be limited to seats

http://www.natep.org.uk/



Partners and their roles in the Project • Lead partner with 80 years of magnesium alloy

development experience.

• End User (non-funded) with 30 years aircraft

interiors experience. European based passenger

seat manufacturer for Aircraft OEMs.

• Leading global service provider of precision-forged

and machined components in titanium, aluminium

and special steels.

• Specialist machinist - Aerospace, Defence, Oil &

Gas and Communications - with 5 axis capability.

• A world leader in virtual design solutions with a 20

year track record in developing better products

across industries including Auto, Aero, Defence and

Consumer.

• Advanced Manufacturing Research Centre (AMRC)

with Boeing is a world-class centre for advanced

machining and materials research for aerospace

and other high-value manufacturing sectors

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=zfsnDbKSRHsdHM&tbnid=0IIMvL3HgdPhKM:&ved=0CAUQjRw&url=http://www.kenard.com/&ei=8xh6U7KnO6OR7AastYBo&bvm=bv.66917471,d.ZWU&psig=AFQjCNHPyivst3XGwJEd0PdHKtmXQ6PCXA&ust=1400597101871379

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=8yZtyKo6_VnIjM&tbnid=Iqc6zn7FLUhK5M:&ved=0CAUQjRw&url=http://www.campaniaerospace.it/index.php?option=com_content&task=view&id=10&Itemid=10&partecipante=108&ei=FBl6U5TcDeig7Abq4IHABQ&bvm=bv.66917471,d.ZWU&psig=AFQjCNGJUn2innphcmSY1gs3r6i7GvuH3w&ust=1400597137556477

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=h19ChFP_Kom9rM&tbnid=V14Uz0n1dxV8cM:&ved=0CAUQjRw&url=http://solarracing.gatech.edu/node/29&ei=cBl6U5zwB-ee7Abr-4GIDg&bvm=bv.66917471,d.ZWU&psig=AFQjCNHHQ4vPBWPAcew_ZOjbiWAPQw7-NQ&ust=1400597230570020

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwitr8mlgqPLAhXCvBQKHbNXAVwQjRwIBw&url=http://www.amrc.co.uk/&bvm=bv.115339255,d.d24&psig=AFQjCNFY1SX0_kk8SgbKJ3CvP6XOwDAOJg&ust=1457042997849028



Part Selection

Piuma EVO seat put forward for project by Geven

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=8yZtyKo6_VnIjM&tbnid=Iqc6zn7FLUhK5M:&ved=0CAUQjRw&url=http://www.campaniaerospace.it/index.php?option=com_content&task=view&id=10&Itemid=10&partecipante=108&ei=FBl6U5TcDeig7Abq4IHABQ&bvm=bv.66917471,d.ZWU&psig=AFQjCNGJUn2innphcmSY1gs3r6i7GvuH3w&ust=1400597137556477



High strength

Mg alloy

Elektron® 43

Lightweight

Aircraft Seat

components

WP2

Forging

WP4

Machining

WP5

Recycling

WP6

Product costs

WP3

Specification •ASTM / AMS

Project Innovation – Work packages

WP7

Validation

and Testing

WP1

Component design •FEA

•HSR Data



Elektron®43 High specific strength & energy absorption @ HSR

WP1

Component design

Project Innovation – Highlights WP1

External experts used when required

Genuine Design for Manufacture



Altair Product Design Approach



NATEP FEA Design Development Process

Loads Development

• Develop equivalent static load cases

Topology Optimisation

• Use Topology (concept) optimisation to establish load paths.

• Interpret topology results into a new baseline designs.

Size and Shape

Optimisation

• Develop and parameterise an FE model from the new baseline

• Run size and shape (refinement) optimisation to tune the design under static load conditions

Design Verification

• Up to seven dynamic and static test simulations will be performed to verify the optimized design including forward, upward, downward and sideward cases



• Material Properties for Elektron® 43 vs Aluminium 2024 – T351

Development of FEM – Material Data

Property Magnesium

(Elektron® 43)

Aluminium 2024 T351

Youngs Modulus

Poissons Ratio

Density

Yield Stress

UTS

Specific Strength

Elongation

44 GPa

0.27

1840 kg/m3

240 MPa

350 MPa

190 MPa/(g/cm3)

12%

73.1 GPa

0.33

2780 kg/m3

324 MPa

469 MPa

170 MPa/(g/cm3)

6%

• High quality data suitable for non-linear dynamic modelling

• Material model requires family of true stress vs true plastic

strain curves for rate range

• Strain rate up to 500/s generated at specialist test house

• Elektron®43: High specific strength, high strain hardening

behaviour and excellent energy absorption characteristics



Development of Finite Element Model

• Mid Surfaced Seat Assembly FE

Model created in HyperMesh

suitable for Dynamic and Static

Assessment



FE Modelling and Load Case Definition • Equivalent Static Load Cases

Defined for Design Purposes

– 16g Forward

– 14g Down

– 16g Fwd -ATD Restraints

– Static 12.0G FWD

– Static 4.0G Sideward

– Static 7.2G Upward

– Static 11.5G Down

• Load cases are defined from peak

test reaction forces

• Static analysis performed using

OptiStruct and Dynamic analysis

using RADIOSS

• Dynamic Loading to Represent

Physical Test

– Dynamic Model Developed using

Hybrid III dummy models

– Dynamic Simulations to be

defined to represent test cases



Design Space Definition

• Design Space geometry defined to

encapsulate existing structure and to add

additional space for new stiffening options

• Integrated with current seat structural model

using similar modelling strategy to seat

structure model

• Sub–Model created to focus on design space

and capture boundary conditions



Topology Concept Definitions

• OptiStruct topological optimisation to define architectures

• Simplified static load cases to represent key loading requirements



Example Analysis (based on 16g FWD reactions)



• Testing carried out on machined demo parts

• Material not forged, but used as early indicator of performance and

potential success.

Model verification – preliminary testing



Final Design –

19% weight saving vs existing Al 2024 – T351

Material / Component weight

saving (%)

Aluminium 2024

Spreader:

Front Leg:

Elektron 43 Mg Rev 3

Spreader 21

Front Leg 21

Elektron 43 Mg Rev 4

Spreader 19

Front Leg 19



High strength

Mg alloy

Elektron® 43

Lightweight

Aircraft Seat

components

WP4

Machining

WP5

Recycling

WP6

Product costs

WP3


WP7

Validation

and Testing

WP1


•HSR Data

WP2

Forging




• Reducing Buy to Fly ratio through forge process

WP2 – Forging Development

Machining Pre-NATEP NATEP

Buy-to-Fly

ratio

10 : 1 4.4 : 1 3.3 : 1

% yield (F2B) 10 % 22 % 31 %

Extruded bar

feedstock

Pre-NATEP –

excess flash

Improved forge

process –

reduced flash

WP2

Forging



0

5

10

15

20

25

30

35

40

45

50

0

50

100

150

200

250

300

350

400

Elektron 43 - T5 - Extrusion Elektron43-T5 forge spreader

Str

en

gth

(M

Pa)

Elo

ngatio

n (%

)

Elektron ® 43 – Tensile Isotropy forge vs. ext.

0° 45° 90° 0° 45° 90°



High strength

Mg alloy

Elektron® 43

Lightweight

Aircraft Seat

components

WP2

Forging

WP5

Recycling

WP6

Product costs

WP3


WP7

Validation

and Testing

WP1


•HSR Data

WP4

Machining




• Baseline dry machining characteristics vs aluminium

– Parts machined on Vertical Milling Centre.

– Standard (Aluminium grade) tooling used

• Depth of cuts +35% compared to Aluminium.

• Feedrate +40% compared to Aluminium.

• Cycle time saving of approximately 35%.

WP4 – Dry machining Elektron®43 WP4

Machining

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=zfsnDbKSRHsdHM&tbnid=0IIMvL3HgdPhKM:&ved=0CAUQjRw&url=http://www.kenard.com/&ei=8xh6U7KnO6OR7AastYBo&bvm=bv.66917471,d.ZWU&psig=AFQjCNHPyivst3XGwJEd0PdHKtmXQ6PCXA&ust=1400597101871379



High strength

Mg alloy

Elektron® 43

Lightweight

Aircraft Seat

components

WP2

Forging

WP4

Machining

WP5

Recycling

WP6

Product costs

WP3


WP1


•HSR Data

WP7

Validation

and Testing




Successful 16G Dynamic Test



Agenda

• Introduction to










• Summary



» Significant weight saving of Elektron®43 vs high strength aluminium

alloy 2024

• Successful 16g dynamic testing

» Capabilities developed in the forging of a magnesium alloy suitable

for aerospace applications

» Fast, efficient, dry machining of a magnesium alloy safely

demonstrated.

» The aerospace industry: improved UK supply chain for downstream

processing of magnesium alloys coming out of Magnesium Elektron

Summary



Thank you for listening...

A special thank you to all of the following people:

• Martin Kemp and the Altair Product Design team – UK

• Pete Bishop and Xenofon Gogouvitis – Mettis Aerospace

• Pasquale Rapullini and Bonaventura Vitolo – Geven

• Martyn Alderman and Steve Montisci – MEUK

• Steve Batsford and Richard Elvins – Kenard

• Nacho Blanco, Erdem Ozturk and Omer Ozkirimli - AMRC

• Rohima Begum, Rory Barker, Phil Rogers and many others

in the technical department at MEUK

http://www.google.co.uk/url?sa=i&rct=j&q=feather&source=images&cd=&docid=FvvK6laUwMpLTM&tbnid=5s2luRetONBtCM:&ved=0CAUQjRw&url=http://chuckgreaves.com/monthly-post/the-weight-of-a-feather/&ei=5oyCUYCmKoXB0gWMxoGACg&bvm=bv.45921128,d.d2k&psig=AFQjCNGH9yDIoSw2Nt75kxKqSzovMkLhaQ&ust=1367596622768396

http://www.google.co.uk/url?sa=i&rct=j&q=magnesium&source=images&cd=&cad=rja&docid=YhWSG1TRdwXS2M&tbnid=Ef256VEeqEFQSM:&ved=0CAUQjRw&url=http://organicconnectmag.com/wp/magnesium-the-mineral-we-cant-live-without/&ei=_4qDUZncEorJ0QXojoDQDA&bvm=bv.45960087,d.d2k&psig=AFQjCNFXy-3r2sZefw-qPTT6arBVWeC22g&ust=1367661479971064


EXCELLENCE • ACCOUNTABILITY • INNOVATION HEALTHCARE PROTECTION SPECIALITY ENVIRONMENTAL

Dr. Dominic Henry

[email protected]

Development of a Lightweight Forged Magnesium Aircraft ... · Development of a Lightweight Forged...

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